ENGINEERING, LLC - Superchargers Online...2020/03/04 · 4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until the problem is resolved

DP/N: 4GN020-015 - v2.0 10/20/08

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1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226 Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

GM ALPHAH3 HUMMERSupercharger SystemInstallation Instructions2008 Model Years

50 State Smog Legal per CARB EO #D-213-27

P/N: 4GN020-015 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0) ii

FOREWORD

Take note of the following before proceeding: 1. Proper installation of this supercharger kit requires general

automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please contact your dealer or Vortech Engineering for possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use

(no boost) until the problem is resolved.5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations include, but not limited to:1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.2. Continued operation with an impaired vehicle or sub-system.3. The combined use of Vortech components with other modifications such as, but not limit-

ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM program-ming or other such changes.

©2008 VORTECH ENGINEERING, LLC All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated

into another language in any form, by any means without written permission of Vortech Engineering, LLC.

This manual provides information on the installation, maintenance and service of the Vortech supercharger kit expressly designed for this vehicle. All information, illustra-tions and specifications contained herein are based on the latest product information

available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0228 8:00am-4:30pm PST.

P/N: 4GN020-015 ©2008 Vortech Engineering, LLC

All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0)iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiTABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiIMPORTANT NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivTOOL & SUPPLY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vPARTS LIST (2008 H3 HUMMER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi1. PREPARATION/REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. OIL DRAIN INSTALLATION (OIL FED MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . 33. OIL FEED INSTALLATION (OIL FED MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . 44. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION . . . . . . . . . . . . . 66. RADIATOR HOSE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138. AIR INLET INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178. AIR INLET INSTALLATION "TEMPLATE" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199. PCV VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2110. FINAL CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

P/N: 4GN020-015 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0) iv

This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive property of Vortech Engineering, LLC. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC.

HUMMER H3IMPORTANT NOTES

2008 ModelsThis kit requires the installation of a Vortech ECU Reflash. The ECU must be sent directly to Vortech by the installing customer (the charge for this service with reflash installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Vortech ECU Reflash.

• An ECU reflash is created specifically for each individual vehicle with respect to the factory ECU calibration.

• Simply contact the Vortech Service Department at (805) 247-0226 to request a Return Authorization Number (See ECM Module Credit Tag for more details).

- Mail to Vortech the enclosed "ECU Reflash" (send original tag - no pho-tocopies will be accepted) and ECU in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Vortech will give an estimate at the time of your order.

Your Vortech ECU Reflash comes with a twelve (12) month limited warranty from the original date of purchase of your supercharger system (see Owner's Manual for details).

Note: Vortech Engineering is not responsible for engine or ECU damage due to an improperly installed/mishandled ECU.


All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0)v

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form.Vortech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech Engineering is not responsible for engine damage.Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).2. The engine must have stock compression ratio.3. If the engine has been modified in any way, check with Vortech prior to using this product.4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is

resolved.5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehi-

cle. Thereafter, always use a manufacture-rated, high grade engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every at least 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS• Factory Repair Manual• 3/8" Socket and Drive Set: SAE & Metric • 1/2" Socket and Drive Set: SAE & Metric• 3/8" NPT Tap, 1/4 -20 Tap and Handle• Adjustable Wrench • Open End Wrenches: 3/8", 7/16", 1/2", 9/16", 7/8”, 10mm• Center Punch and a 5/8" Tapered Punch• 3/8” Springlock Fuel Fitting Disconnect Tool• 5 Quarts manufacturer specified Engine Oil• Oil Filter and Wrench• Flat #2 Screwdriver• Phillips #2 Screwdriver• Heavy Grease• Silicone Sealer• Drill Motor • 1/8", 3/16", 27/64" Drill Bits• 5/16" Allen Wrench• Wire Strippers and Crimpers• Utility Knife• Power Steering Pulley/Puller & Installer

If your vehicle has in excess of 15,000 miles since its last spark plug change, then you will also need:• Spark Plug Socket• NEW Spark Plugs

GM 2008 H3 HummerInstallation Instructions

®

ENGINEERING, LLC

Congratulations on selecting the best performing and best backed automotive supercharger available today... the VORTECH® Supercharger!

50-State Smog Legal, as per CARB EO # D-213-27

P/N: 4GN020-015 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0) vi

2F328-030 V3 SC-TRIM,CW,CRVD,STN,H3-A 12A036-333 S/C PULLEY 3.33" 6 GROOVE 1

4GN111-051 ASSY, MNTG BRKT H3 ALPHA 14GN011-051 BRKT, S/C MNT H3 ALPHA 14GN011-061 BRKT, SPRT H3 ALPHA 14GN017-011 SPACER, S/C MNT TOP H3 ALPHA 14GN017-021 SPACER, S/C MNT LWR H3 ALPHA 12A017-102-299 SPACER, 1"OD X .406"ID X 2.992" 12A017-875-198 SPACER, .875"OD X .406"ID X 1.98 22A017-625-025 SPACER, .625"OD X .375"ID X .025" 17C010-025 M10-1.5 X 25MM HXCSP 17C010-111 M10 X 1.5 X 110 HXHD, ZINC 17C010-120 M10 X 1.5 X 120 HXHD, ZINC 17C010-130 M10 X 1.50 X 130 HEX HEAD 17A375-124 3/8-16 X 1-1/4 HHCS, G5, PLATED 47A375-352 3/8-16 X 3.5" HX HD GR8 17A375-075 3/8-16 X 3/4 GR5 HXHD ZINC 17A375-400 3/8-16 X 4" BOLT HXHD GR8 37A375-426 3/8-16 X 4.25" HX HD GR8 17K375-040 3/8 AN960 FLAT WASHR PLATED 134FR016-150 STEEL IDLR PLY, 3" 6 RIB SMOOTH 14FH016-150 IDLER PULY, 6RIB 3" FLANGD 12A017-177 SPACER, Ø.875 X 1.772 W/PLT 12A017-016 PILOT, 6203/5 BRG, 3/8 SCREW 12A046-114 BELT, K061145-GATES 4.6 2V 17J750-394 SPACER, .375/M10 IMPELLER NUT 17J625-030 SHIM, Ø.692" ID X .030" THK X 1

8N201-340 CHARGE COOLR ASY, 08, H3 ALPHA 8N101-340 WELDED CORE ASSY, H3 ALPHA 18N055-050 PLASTIC CAP, SURGE TANK 17R002-044 #44 SAE TYPE F SS HOSE CLAMP 27S275-500 SLEEVE, 2.75" X 5.00"L, BLUE 17S300-300 SLEEVE, 3" X 3", BLUE 14GN012-020 DUCT, DISC. H3 ALPHA 14GL012-030 ELBOW,3.88"-3.0" X 90 GM TRK 17R002-048 #48 SAE TYPE F SS HOSE CLAMP 37R002-060 #60 SAE TYPE F SS HOSE CLAMPS 18F001-402 PUMP, WATER, PIERBURG 17R003-027 ADEL CLAMP,1-11/16" 27E010-075 #12 X 3/4" SHT METL SCRW HEX 27U030-046 5/32" VACUUM LINE 1.58D001-001 STD COMPRESS BYPASS VALVE 17U034-016 1" GS HEATER HOSE 0.837R002-016 #16 SAE TYPE F SS HOSE CLAMP 48N010-230 BRKT, UPR SPRT SETRAB H3 18N010-240 BRKT, SETRAB MNT H3 18N006-010 WATER COOLR, SETRAB SINGLE PASS 17P500-026 1/2NPT X 3/4 BARB 90 BRASS 17P500-078 1/2NPT X 3/4 HOSE FIT STRT 37P375-075 3/4" HOSE BARB UNION, BRASS 17U038-012 HOSE,3/4"DIA 90 ,4X12 LEGS 27U038-150 HOSE, 3/4"X150 MOLDED HOSE 14GV014-010 WATER PIPE, L BEND 17U038-000 3/4" HEATER HOSE 4.337R007-001 NYLON RATCHET CLAMP 1-1/8" 105W001-015 FUSE, BLADE TYPE 20 AMP 15W001-071 FUSE HOLDER,16GA WIRE 15W018-020 18GA STRD WIRE BLK, UL1015 55W001-024 MINI ATC FUSE TAP 15W001-025 FEM SLIDE,INSUL,MINI,22-16AWG 15W001-012 18-22 GA BUTT CONN RED INSUL 17C080-016 M8 X 1.25 X 16 HXHD 15W001-046 16-14 GA RING TERM .33" HOLE 1

4GN112-030 AIR INLET ASSY, H3 ALPHA 4GN013-010 AIR CLEANER COVER, H3 14GN013-020 BRACKET, AIR FILTER CVR SPRT 17S350-200 SLEEVE, 3-1/2 X 2, BLUE 28H040-235 AIR FILTER, 4.0FLG X 7.0L 17F006-093 6MM NYLOCK NUT 17A250-063 1/4-20 X .63 HHCS SS 2

7S350-350 ELBOW,Ø3.5" 90 DEG W/BUNG 14FA012-012 INTAKE ELBOW,90 DEG W/O BOSSES 17R002-056 #56 SAE TYPE F SS HOSE CLAMP 48A002-041 MAF, 2008 H3 ALPHA Ø3.44" ID 17C040-008 M4-.7X8MM SCHD SS 27A250-074 1/4-20 X .75 HHCS PLTD 27A250-101 1/4-20 X 1 HHCS ZINC PLTD 17J250-001 1/4 WASHER, SAE, PLTD 67U035-001 3-1/2" FLEX HOSE 0.837R002-052 #52 SAE TYPE F SS HOSE CLAMP 27U032-016 3/8" EFI FUEL HSE HI-PSR 17P375-050 3/8" HOSE UNION, BRASS 17P375-037 3/8 NPT MALE X 3/8 HSE BARB 90º 14GN013-030 SHIELD, SPUND SPR 14GN125-100 SOUND ABS. MAT 1

4GN139-098 PCV MOD ASSY, H3 ALPHA 17P375-106 PCV VALVE, FORD, 3/8" HOSE 17P625-377 REDUCER, 5/8 BARB TO 3/8 BARB 17R001-008 #8 STNLS HOSE CLAMP 17R004-002 STEPLESS CLAMP, 17.0-70 27U033-020 HOSE, 5/8"ID CLASS 1 EMISSIONS FUEL 0.125

4GN114-020 COOLANT PIPE ASSY. H3 ALPHA 17R002-020 #20 SAE TYPE F SS HOSE CLAMP 24GN014-020 RAD. PIPE Ø1.375, H3 ALPHA 14GN014-010 TUBE ASSY.,Ø.75 X 2.5 X 4.5 X 75° 17U133-024 5/8"MOLDED ELBOW HSE, 24" 17U038-012 HOSE,3/4"DIA 90 ,4X12 LEGS 17P375-075 3/4" HOSE BARB UNION, BRASS 17P625-016 5/8" HOSE UNION, BARBED ENDS 17R003-016 ADEL CLAMP, 1.0" 17R001-008 #8 STNLS HOSE CLAMP 4

8F060-047 FUEL INJ 47LB, DELPHI MULTEC 3.5 SHORT 84GN020-015 INSTR MAN, H3 ALPHA HUMMER 1008110 SMALL SILVER DIE CUT DECAL 2008130 LICENSE PLATE FRAME, VORTECH 1008447 S/C STRT INFO PKG ASSY VORT 1009035 LUBE ASSY 1

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.

GM 2008 H3 Alpha HummerPart No. 4GN218-040L

®

ENGINEERING, LLC PARTS LIST


All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0)1

A. Disconnect the negative battery cable, and remove the plastic engine cover.

B. Disconnect the MAF electronics harness con-nection from the meter. (See Fig. 1-a)

C. Disconnect the passenger side valve cover vent line fom the valve cover. Remove the 90° rubber elbow and set aside to be reused in a later step.

D. Using a 5/16” nut driver, loosen the hose clamp securing the inlet duct to the throttle body. Remove the air filter lid and inlet duct to the throttle-body. (See Fig. 1-b)

E. Disconnect the MAF harness from the lower half of the air box. Using a 13mm socket and long extension remove the fasteners retaining the lower portion of the air filter enclosure to the inner fender. Set the air box aside, it will not be reused.

F. Remove the MAF electronics from the previ-ously removed air filter assembly and set aside to be reused in a later step. (See Fig. 1-a)

G. Using a 15mm wrench detention the factory belt tensioner and remove the accessory belt.

H. Remove the three 15mm headed retainers securing the factory belt tensioner to the water pump.

I. Remove the front skid plate and set aside. Drain the engine coolant into a clean contain-er and set aside to be reused in a later step. Once the coolant is drained remove the retainer securing the heater hose support bracket to the front of the passenger side cyl-inder head. (See Fig. 1-c & 1-d)

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

NOTE:

1. Locate the vehicles ECU and TCM modules behind the washer fluid/coolant reservoir assembly passenger side firewall.

2. Temporarily loosen the washer fluid/coolant reservoir assembly to gain adequate access to the modules.

3. Unplug the four factory harness connections and remove the modules from the vehicle.

4. Contact the Vortech Service Department for a Return Authorization Number. Send both the ECU and TCM and supplied credit tag to Vortech using the enclosed shipping materials.

P/N: 4GN020-015 ©2008 Vortech Engineering, LLC All Rights Reserved, Intl. Copr. Secured 20OCT08 v2.0 08HummrH3(4GNv1.0) 2

Fig. 1-d

Fig. 1-e

Fig. 1-f

1. PREPARATION/REMOVAL, CONT’D.

J. Disconnect the 1/4" coolant line from the heater hose assembly. Disconnect the heater hoses where they attach to the water pump and fire wall on the passenger side. Remove the heater hose assembly and set aside. (See Fig. 1-d & 1-e)

K. Remove the stud that formerly retained the front drivers side corner of the engine cover and discard. (See Fig. 1-f)

STUD

HEATER HOSE SUPPORT BRACKET

1/4" LINE



A. Locate and remove the fasteners that secure the factory transmission cooler to the front cross-member. Push the cooler up and tem-porarily secure out of the way. (See Fig. 2-a)

B. Remove the 10mm headed fastener that secures the plastic wire loom to the front of the oil pan. (See Fig. 2-b)

C. Mark the hole location as shown on the front of the pan. Center punch the hole location to be drilled. (See Fig. 2-c)

D. Drill an 1/8” pilot hole at the previously marked location. Locate the oil drain assem-bly (4GN130-036). Use the supplied 9/16” cutter to enlarge the pilot hole, making sure to break through easily. Do not stop the drill motor until the cutter has been extracted so that the cutout does not fall into the pan. It may help to pack the cutting tool with grease to help prevent any stray chips from entering the oil pan.

E. Thread the hole with a 3/8” NPT tap to approximately 1/2" deep or until the fitting can be started. Pack the flutes of the tap with grease to minimize the amount of debris that gets into the engine. Access is restricted so inserting the tap in a socket and then using a ratchet to rotate it is helpful.

F. Thoroughly clean the threaded area and the interior of the engine. Apply a small amount of silicone sealer to the new threads. Apply more sealer to the 3/8” NPT MALE X .5 FEMAL INVERTED FLARE hose fitting and secure in the hole. Make sure a seal is formed all around the fitting. (See Fig. 2-d)

G. Loosely install the TUBE NUT ASSEMBLY into the previously install fitting. The super-charger oil drain hose connection will be made in a later step. Leave the transmission cooler and wire loom loose until then. (See Fig. 2-d)

H. Drain the engine oil and change the filter.

Fig. 2-a

Fig. 2-b

Fig. 2-c

2. OIL DRAIN INSTALLATION (ENGINE OIL-FED KITS ONLY. APPLICA-TIONS WITH V3 SUPERCHARGERS SKIP AHEAD TO STEP 4)NOTE: To provide an oil drain for the supercharger,

it is necessary to make a hole in the oil pan.

NOTE: When tapping the hole be careful not to bottom out the tap. If the tap does bottom before the thread is large enough you will need to trim the end of the tap to facilitate a deep enough thread cut.

TRANSMISSION COOLER

Fig. 2-d

1.5"2 5/8"


Fig. 3-a

A. Install the 1/8” NPT x 90° -4 fitting into the supplied oil feed adaptor as seen in figure 3-a.

B. Locate the factory oil passage cover just above the oil filter on the driver’s side of the engine. Using a 10mm socket remove the factory retainers and discard.

C. Using the new gaskets and 6mm hardware provided reinstall the factory oil passage cover and oil feed adapter. The 90° fitting should be facing the front of the vehicle. (See Fig. 3-b)

D. Attach one end of the supplied –4 stainless steel oil line to the previously installed –4 x 90° fitting and secure. (See Fig. 3-b)

E. Route the line toward the front of the engine and up to where it will be attached to the supercharger oil feed. Using the supplied cable ties secure the line away from hot, sharp or moving parts. (See Fig. 3-c)

F. Cover the open end of the line to prevent contamination until the connection to the supercharger is made in a later step.

3. OIL FEED INSTALLATION (ENGINE OIL-FED KITS ONLY. APPLICA-TIONS WITH V3 SUPERCHARGERS SKIP AHEAD TO STEP 4)

Fig. 3-b

Fig. 3-c

OIL FEED LINE



4. FUEL INJECTOR REPLACEMENT

A. Relieve the fuel system pressure.B. Disconnect the eight fuel injector wiring clips

and retainers from the injectors.C. Remove the four 8mm bolts securing the fuel

rails to the intake manifold. Lift up on the rails evenly, removing all eight injectors. Separate and set aside the factory injectors as they will not be re-used.

D. Using a small amount of clean motor oil, lightly lubricate the O-rings on both ends of the supplied fuel injectors.

E. Install the new fuel injectors into the fuel rails and secure using the factory retaining clips.

F. Carefully lower the fuel rail-injector assembly down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

G. Secure the fuel rail assembly using the origi-nal hardware and attach the wiring clips to the injector terminals.

NOTE: Caution should be used when working on the fuel system. Fuel may be under high pressure. Fuel injector replacement should be performed in a well ventilated area free of any possible ignition source. It is recom-mended that you have a fire extinguisher nearby.

NOTE: The injector plug connections must face outwards.


Fig. 5-b

Fig. 5-c

Fig. 5-d

A. Locate the supercharger mounting bracket assembly (4GN111-051)

B. Clearance (grind) the end of the passenger side valve cover flush with the head surface. (See Fig. 5-a)

C. Install the support bracket to the passenger side cylinder head using the M10 X 25mm screw and washer. Make sure the head sur-face is clean and no wires or hoses are between the bracket and mounting surface. Loosely install one of the factory tensioner mounting retainers in the lower cylinder head hole location as a guild. Tighten the previous-ly installed M10 screw. Remove the tensioner retainer used as a guild. (See Fig. 5-b)

D. Using two 3/8-16 x 4” screws and the lower bracket spacer, loosely install the supercharg-er mounting bracket.

E. Install one of the Ø1.0” x 2.992” spacer using the M10 x 110mm screw, do not use a wash-er when installing this fastener as tensioner bracket interference will result. (See Fig. 5-c)

F. Using a one of the factory tensioner retainers, M10 x 120mm, and 3/8-16 x 4” retainers and washers install the upper (three hole) spacer between the supercharger bracket and the previously installed support bracket. Tighten all hardware installed to this point. (See Fig. 5-c)

G. Locate the factory spring tensioner and sup-plied mounting hardware: Place the 0.121” thick washer onto the M10 x 130mm screw and insert it through the factory spring ten-sioner. Insert the 3/8-16 x 4.25” screw and washer through the tensioner. Place the two Ø.875” x 1.98” spacers on the previously installed hardware. Insert the 3/8-16 x .75” screw and washer through the remaining ten-sioner hole and place the .025” spacer on it. Carefully install this assembly. The M10 screw will go through the support bracket and into the head. The 3/8-16 x 4.25” screw secures to the support bracket. And the 3/8-16 x .75” screw secure to the supercharger mounting bracket. (See Fig. 5-d, 5-l, 5-m)

NOTE: For the following section, refer to Fig 5-l & Fig. 5-m on page 10 and 11, for screw and spacer location. Do not tighten until instructed to.

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

M10 x 25mm

M10 x 110mm

Fig. 5-a



Fig. 5-e

Fig. 5-f

Fig. 5-g

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, CONT’D.

H. Remove the 15mm headed screw securing the ribbed tensioner pulley to the tensioner arm. Install the supplied 3” steel smooth idler and secure using the factory hardware and Ø.692" I.D x .030" thick spacer.

I. Locate the coolant pipe assembly (4GN114-020). Secure the Ø3/4” x 90° and Ø5/8” x 90° molded hoses to their corresponding water pump ports using the factory hose clamps from the previously removed hose assembly. (See Fig. 5-e)

J. Using the supplied adel clamp secure the Ø5/8” hose to the coil (front passenger side) retainer. Route the hose to the heater core connection at the firewall. Locate and cut the factory heater hose assembly to obtain the factory clip connectors (leave yourself extra hose and trim as necessary) set the 3/4" con-nector aside. Connect the factory 5/8” clip connector to the heater core. Use the sup-plied Ø5/8” union and hose clamps to con-nect the previously installed mold hose to the factory heater hose (trim as necessary for best fit). (See Fig. 1-f, 5-f & 5-g)

Ø 5/8" HOSE

Ø 3/4" HOSE

ADEL CLAMP

COIL

FACTORY 5/8" HOSE UNION

5/8" HOSE


Fig. 5-h


K. Install the Ø3/4” aluminum 105° tube into the open end of the previously installed Ø3/4” molded 90° hose (the 1/4" barb should face slightly forward). Connect the factory 3/4" clip connector to the heater core. Insert the open end of the 105° aluminum tube into the open end of the factory 3/4" hose. Secure all hose connections with the provided hose clamps. Secure the factory 1/4" bleed hose to the 1/4" barb on the 105° aluminum tube. (See Fig. 5-h)

L. (OIL-FED MODELS ONLY) Using one of the supplied #6 hose clamps secure the provided 1/2" oil drain hose to the 1/2" oil drain fitting on the bottom of the supercharger. (See Fig. 5-i)

M. Mount the supercharger to the supercharger bracket using the four 3/8-16 x 1.25” screws and washers. Attach the supplied 3” flanged smooth idler to the mounting bracket using the Ø.875” x 1.772” piloted spacer, 3/8-16 x 3.5” screw, and pilot washer. (See Fig. 5-j, & 5-k, 5-l)

N. (OIL-FED MODELS ONLY) Install the 1/8”NPT x 90° x –4 fitting into the super-charger oil feed port and orient so it faces down. (See Fig. 5-j)

Fig. 5-i

Fig. 5-j

FACTORY Ø 3/4" HOSE

1/4" BLEED HOSE

105° ALUMINUM TUBE

Ø 3/4" MOLDED 90°HOSE

1/8 NPT x 90° x -4

3" FLANGED SMOOTH IDLER



Fig. 5-k


O. (OIL-FED MODELS ONLY) Connect the 1/2" oil drain hose from the S/C to the 1/2" tube assembly previously installed in the oil pan and secure. Using a cable tie secure the line to the A/C line away from the A/C pulley

P. (OIL-FED MODELS ONLY) Connect the open end of the –4 stainless steel oil feed line to the –4 x 90° fitting on the supercharger.

Q. Install the supplied drive belt as shown. (See Fig. 5-k)

S/C

3”FLANGED

IDLERALT.

IDLER

TENSIONERWATERPUMP

POWERSTEERING

CRANK

NOTE: Ensure that the hose does not have any dips or kinks in the routing. Supercharger failure may be the result of a restricted drain path.



3/8-16 X 3.5” WITH PILOT WASHER

3/8-16 X 4”

M10-1.5 X 120MM

FACTORY TENSIONERRETAINER

M10-1.5 X 25MM

3/8-16 X 4.25”

M10 - 1.5 X 130MM & 0.121” THICK WASHER

M10 - 1.5 x 110MM NO WASHER

3/8-16 X 4”

3/8-16 X .75”

3/8-16 X 4”

4 X 3/8-16 X 1.25”

Fig. 5-l



Fig. 5-m

UPPER (3 HOLE) SPACERLOCATED BETWEEN S/CBRACKET AND SUPPORT

BRACKET

Ø .625” X .025” SPACERLOCATED UNDER TENSIONER

MOUNTING BOSS

LOWER (2 HOLE) SPACERLOCATED BETWEEN S/CBRACKET AND SUPPORT

BRACKET

Ø1.0” X 2.992” SPACERLOCATED BETWEEN S/CBRACKET AND SUPPORT

BRACKET

Ø0.875” X 1.98 SPACERSLOCATED UNDER TENSIONER

MOUNT BOSSES



6. RADIATOR HOSE MODIFICATION

A. Locate the upper radiator hose.B. Cut the hose after the 45° leaving as much

straighht section as possible (approximately 1"). See Fig. 6-a.

C. Make a second cut approximately 2" before the 90° bend. See Fig. 6-a.

D. Install the provided stainless steel radiator tube and secure using the supplied #20 hose clamps. See Fig. 6-b.

NOTE: Adjust the hose ends as necessary to pro-vide the best possible drive belt and idler pulley clearance.

Fig. 6-a

Fig. 6-b



Fig. 7-a

Fig. 7-c

Fig. 7-b

7. CHARGE COOLER INSTALLATION

Refer to Fig.7-h for assistance throughout this manual.A. Remove the four screws and two nuts that

secure the grill to the core support.B. Pull forward on the ends of the grill to release

the push clips holding the grill in place.C. Locate the Charge Air Cooler assembly

(8N201-340).D. Install one 1/2"NPT x 3/4" barb 90° brass

elbow and one 1/2"NPT x 3/4" barb straight fitting into the supplied heat exchanger and orient as shown*. (See Fig. 7-h.)

E. Remove the two 13mm headed screws and two 10mm headed screws securing the hood latch support assembly to the core support. Unclip the wire harness that runs behind the support. Set the support aside to be reinstalled later. (See Fig. 7-a.)

F. Secure the heat exchanger bracket (8N010-240) to the heat exchanger using the 1/4-20 x .75" screws, washers and Nyloc nuts provided. Loosely install the heat exchanger assembly into position. (See Fig. 7-a, 7-h.)

G. Reinstall the hood latch support (the heat exchanger bracket is between the core sup-port and the hood latch support) secure using the factory hardware. Feed the sensor leads through their respective sides and reconnect to the sensors.

H. Place the supplied piece of 1/8" x 4" tape foam on the heat exchanger. It may be necessary to trim the tape to fit. Install the upper heat exchanger bracket and secure using a 1/4-20 x .75" screw, washer and Nyloc nut provided. (See Fig. 7-b.)

I. Using the supplied Adel clamps, self-tapping screws and washers, secure the provided water pump, to the cooling fan shroud. (See Fig. 7-c.)

J. Secure the supplied Ø2.75" X 5" sleeve to the supercharger discharge using a #44 hose clamp. (See Fig. 7-d.)

K. Using the supplied Ø3.88” to Ø3.0” reducer elbow and Ø3.0” x 3” sleeve, install the dis-charge duct between the CAC and the throttle body, secure using the #48 & #60 hose clamps provided. See Fig 7-d)

NOTE: Careful not to pinch wires between the brackets.

NOTE: Orient the pump discharge so that it points to the front passenger side of the vehicle.

150° MOLDED HOSE Latch

Support

90° HOSE

150° HOSEHOSE FROM CAC

WATER PUMP

* Use pipe sealant on tapered pipe threads.


L. Install the two 1/2" NPT x 3/4" barb fittings into the charge air cooler (CAC*).

M. Cut a piece of the supplied Ø3/4" rubber hose (7U038-000) approximately 24" long. Connect the cut hose between the CAC dis-charge (bottom driver’s side fitting) and the water pump inlet as shown. (See Figs. 7-c, 7-d 7-h.)

N. Connect the supplied 150° x Ø3/4" molded rubber hose between the water pump dis-charge and the heat exchanger inlet (passen-ger’s side fitting). (See Figs. 7-a, 7-c, 7-h.)

O. Attach the short end of the supplied molded 90° rubber hose (7U038-012) to the straight fitting previously installed in the heat exchanger (driver’s side fitting). (See Fig. 7-a, 7-h.)

Fig. 7-d

Fig. 7-e

NOTE: Trim the hose as necessary.

* Use pipe sealant on tapered pipe threads.

P. Trim the long end of the previously installed hose to about 1.5". Connect the long end of the formed 150° aluminum tube to the open end of the previously installed 90° molded hose. (See Figs. 7-f, 7-h.)

Q. Connect the long eng of the remaining 90° rubber hose to the aluminum tube. Install the supplied hose union to the open end of the hose. Attach a section (approximately 36” long) of the supplied Ø3/4” heater hose to the previously installed union. Connect the open end of the Ø3/4” hose to the CAC inlet (top passenger side fitting). (See Fig. 7-e, 7-f & 7-h)

7. CHARGE COOLER INSTALLATION, CONT’D.

Fig. 7-f



7. CHARGE COOLER INSTALLATION, cont’d

Fig. 7-g

R. Secure all hose connections at this time using the supplied nylon ratchet clamps. Make sure that all hoses are routed and secured away from hot or moving parts.

S. Using the supplied butt connector, attach the supplied length of wire to the poitive (green) wire on the water pump. Route the wire to the power distribution box (PDB) located on the driver side. Trim the wire so that it just reached the PDB. Connect the supplied fuse holder to the end of the wire. Attach the trimmed piece of wire to the opposite side of the fuse holder. Locate the fuel pump relay. Using the mini ATC fuse tap and the supplied femal spayed connector attach the wire to terminal #87 on the relay. (see Fig. 7-g)

T. Attach the supplied ring terminal to the water pump ground wire. Secure the ground wire to the inner fender using the supplied M8 fas-tener.

U. Fill the CAC coolant using a 25%/75% anti-freeze/water mix. Fill through the surge tank fill port located on the CAC.


Fig. 7-h

CHARGE AIR COOLER

1/2 NPT TO 3/4” HOSEBARB (7P500-078)

(7U038-012)90° A” X 12”FORMED HOSE

WATER PUMP (8F001-402)MOUNTED WITH TWO ADELCLAMPS TO FAN SHROUD 3/4” HOSE (7U038-000)

CUT TO FITAPPROXIMATELY 26”

3/4” HOSE (7U038-000)CUT TO FIT

APPROXIMATELY 23” (7U038-012)90° A” X 12” FORMED HOSE

(TRIMMED TO APPROX 4.5” X 1.5’(7U038-150)150° MOLDED HOSE

(4GV014-010)FORMED ALUMINUM

TUBE

WATER COOLER(8N006-010)

90° 1/2 NPT TO 3/4”HOSE BARB (7P500-026)

1/2 NPT TO 3/4” HOSEBARB (7P500-026)

(8N010-240) HEAT EXCHANGERMOUNTING BRACKET MOUNTEDBETWEEN CORE SUPPORTAND HOOD LATCH SUPPORT

3/4” HOSE UNIONBARBED (7P375-075)

(FRONT VIEW)

7. CHARGE COOLER INSTALLATION, cont’d



Fig. 8-a

Fig. 8-b

Fig. 8-d

8. AIR INLET INSTALLATION

MAF METER

AIR FILTER

FILTER COVER

A. Locate the MAF mounting hole template in this manual. Remove and cut the template as shown. Place the template on the passenger side inner fender and mark the three hole positions to be drilled. Drill the previously marked hole locations using a 1/4" drill.

B. Install the MAF meter into the air filter cover. Place the supplied air filter on to the meter and secure. (See Fig. 8-a.)

C. Install the air filter assembly into the vehicle. Secure the MAF meter and the sound sup-pressor shield to the previously drilled holes in the inner fender using the 1/4-20 hardware provided (the shield goes inside the fender opposite the MAF) (See Figure 8-d.).

D. Secure the forward edge of the air filter hous-ing to the front core support using the sup-plied 90° bracket, 1/4-20 hardware and M6 Nyloc nut. (See Fig. 8-b).

E. Install the previously removed MAF electron-ics into the supplied meter housing and secure using the supplied hardware. Connect the MAF electronics harness to the MAF. (See Figure 8-d)

F. Locate the 3.5” x 90° duct with bosses and install the 3/8”NPT x 3/8” barb x 90° fitting. Secure the 3.5” x 90° duct to the supercharg-er inlet using the Ø3.5” x 2” sleeve and two #56 hose clamps provided. Secure the 90° duct w/out bosses to the previously installed MAF meter using the remaining Ø3.5" x 2" sleeve and two #56 hose clamps. (See Fig. 8-c, 8-d)

G. Connect the provided length of Ø3/8” hose to the previously installed 3/8” barb x 90° fitting. Insert the supplied Ø3/8” hose union into the open end of the hose. Attach the factory 90° molded hose to the previously installed union. Connect the open of the 90° hose to the barb located on the passenger side valve cover. (See Fig. 8-c)

H. Connect the two 90° inlet ducts using the Ø3.5 x 10" flex hose and secure using the remaining #52 hose clamps provided. (See Fig. 8-d.)

I. Cut a piece of the supplied Ø1.0” rubber hose approximately 4” long and secure it to the Ø1” port on the previously installed CAC using the #16 hose clamp provided.

FACTORY MOLDED

90°

Ø3/8" HOSE

Ø3.5" X 90° DUCT 3/8" NPT X

3/8" BARB 90°

3.5” 90° ELBOW w/ BOSSES

MAF METER

3.5” 90° ELBOW w/o BOSSES

Fig. 8-c

SUPPORT BRACKET

NOTE: Trim the 3/8" hose to the best fit. Retain the extra hose to use in a later step.


This Page Left Intentionally Blank



EXIS

TIN

GH

OLE D

RIL

LTH

REE

1/4”

HO

LES

INN

ERFE

ND

ERTE

MPL

ATE

8. AIR INLETINSTALLATION “TEMPLATE”


Fig. 8-e

8. AIR INLET INSTALLATION, cont’d

K. Insert the inlet side of the supplied by-pass valve into the open end of the previously installed hose and orient it so that the open end faces forward and secure using the #16 hose clamp provided. (the vacuum port should be facing down).

L. Using the remaining section of Ø1.0” rubber hose connect the open end of the by-pass valve to the Ø1.0” barb on the previously installed Ø3.5” x 90° duct and secure using the remaining #16 hose clamps provided.

M. Connect the supplied piece of 5/32” vacuum line to the vacuum port on the by-pass valve. Route the line up to the manifold. Locate the vacuum port on the passenger side of the manifold. Cut the sealing tab off the end of the factory vacuum port. Insure that the port is open and free of any debris left from the cutting process. Connect the open end of the previously installed vacuum line to the vacu-um port. (See Fig. 8-e)

N. Reinstall the grill in the reverse order removed, using the factory harware.

SEALING TABVACUUM PORT



9. PCV VALVE INSTALLATION

A. Locate the valve cover vent hose attached between the intake manifold and the rear of the valve cover.

B. Remove the factory 45° molded rubber elbow from the valve cover end of the factory vent tube. (See Fig. 9-a)

C. Cut the factory vent tube just after the 90° bend, leave enough straight section to install the PCV valve. (See Fig. 9-b)

D. Install the 3/8” end of the PCV valve into the open end of the factory vent tube (heating the end of the tube slightly will make inserting the valve easier, use care not the melt the materi-al). (See Fig. 9-b, 9-c)

E. Using the section of Ø5/8” hose provided, attach the 5/8” x 3/8” reducer fitting to the end of the previously installed PCV valve. (See Fig. 9-b)

F. Attach the supplied section of Ø3/8” hose (left over from the intake assembly) to the reducer fitting. Install the provided Ø3/8” hose union into the end of the Ø3/8” hose. Using the fac-tory 45° molded rubber elbow connect the Ø3/8” hose to the barb on the drivers side valve cover. (See Fig. 9-a)

Fig. 9-a

Fig. 9-b

Fig. 9-c

45° MOLDED ELBOW

FACTORY TUBE

PCV VALVE

Ø5/8" HOSE

Ø3/8" HOSE

REDUCER UNION


10. FINAL CHECK

A. If your vehicle has gone over 15,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

B. Check all fitting, nuts, bolts and clamps for tight-ness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps.

C. Check all fluid levels, making sure that your tank(s) is/are filled with 91 octane or higher fuel before commencing test drive.

D. Start the engine and allow to idle a few minutes, then shut-off.

E. Recheck to be sure that no hoses, wires, etc. are near exhaust headers or moving parts. Look also for any signs of fluid leakage.

F. PLEASE TAKE SPECIAL NOTE: operating the vehicle without ALL the subassemblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS.

H.O. Charge Cooled Kits Only

NOTE: Check to see that CAC coolant is flowing through the surge tank. If coolant is not flowing, remove the 3/4” rubber hose from the side of the CAC and apply light suction in an attempt to pass any trapped air in the system. Reconnect the hose and recheck coolant flow.

WARNING: Do not attempt to operate the vehicle until all components are installed and all operations are completed including the final check.

NOTE: Once the Re-flashed ECU and TCM are received back from Vortech, reinstall them in the reverse order removed. Take care not to damage the harness connectors or ECU/TCM connection pins. Re-secure the washer fluid/coolant reservoir assembly.



For internally lubricated V3 units onlyThis supercharger has been factory pre-filled with special Vortech synthetic lubricant. Oil does not need to be added to a brand new unit; however a fluid level check should be per-formed.Prior to operating the supercharger on the vehicle and after installation onto the vehicle:Remove the factory installed flat-head brass shipping plug (not the dipstick) from the top of the supercharger case. Replace the sealed shipping plug with the supplied “vented” plug. Do not operate the supercharger without it. Check the supercharger fluid level. Fluid level checking procedure: 1. Ensure that the .06” copper sealing washer is located on the dipstick base. 2. Thread the clean dipstick into the unit until it seats. 3. Once the dipstick has seated, remove the dipstick from the unit. Fluid should register in the crosshatched area on the dipstick. 4. DO NOT OVERFILL!!! Drain excess fluid from the unit if it is above the maximum level on the dipstick.Check the fluid level using the dipstick at least every 2,500 miles.Initial supercharger fluid change must be performed at 2,500 miles. The supercharger fluid must be changed at least every 7,500 miles.Drain the fluid, refill the unit with 4 oz. of Vortech V3 lubricating fluid and then confirm proper oil level using the dipstick. DO NOT OVERFILL!!!

WARNING: Use of any other fluid other than the special Vortech lubricant will void the warranty and may cause component failure.

10. FINAL CHECK , cont’d

G. Test drive the vehicle.H. Always listen carefully for engine detona-

tion. Discontinue heavy throttle usage if detonation is heard.

I. Read the STREET SUPERCHARGER SYSTEM OWNER’S MANUAL AND RETURN THE WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify.

DP/N: 4GN020-015 - v2.0 10/20/08

®

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226 Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

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ENGINEERING, LLC - Superchargers Online...2020/03/04 · 4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost) until the problem is resolved